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[Manzanita]

So the past couple years my Zero has been sitting around collecting dust, as the battery is cooked with 25k miles on it. I did call the closest dealer and they gave me a quote of $9300 to replace the battery. I am leaning towards selling it cheap ($1500) but the thing is, I do have a 50 mile round trip commute and free charging stations in front of the building I work...

So has anyone built a homemade battery replacement?

I did some rough measurements of the battery box ( ~ 17" x 16.5" x 10" ) and eight 100AH lithium batteries *almost* fit: https://www.amazon.com/Redodo-Mini-4000-15000-Lifetime-Off-Grid/dp/B0BVVWYVHZ?th=1  That would give about 10 kwh at 96 volts for $1600 (well, I don't think it will fit but this is hypothetical). Has anyone tried anything like this?

I do have a tech school degree in electronics, worked as engineering technician in circuit board design groups 10 years, etc. Volts is volts, right? 

[Manzanita]

Here is the thread on my battery issues, if you are curious: https://www.electricmotorcycleforum.com/boards/index.php?topic=12700.0

[MVetter]

Those batteries are NOT designed for a high discharge rate. Very poor choice and also still the wrong voltage for your bike components to operate. Zero's pack is 28S4P with operation between 94-116.4vdc. I would only ever advice using cells meant to have high C rates for discharge aka EV cells: 18650s, 21700s, pouches, etc.

[Specter]

whats the dielectric strength of those batteries?
are they vibe tolerant or meant for standing apps, ie like set on the floor and don't jar them around etc etc

aaron

[MVetter]

Please know it’s for energy storage battery rather than starter or golf cart batteries, and it can be work with 30~70 lbs trolling motor.

no idea m8

[Curt]

It's $6000 to replace the batteries in my FX, which I would gladly do because it would be the most cost-effective way to extend (maybe even double) its life, except that Zero will warrant new batteries for only one year, as opposed to 5 years when purchased in a new bike. I'm quite pissed they will not stand by their high-priced product. Now, not only will I refuse to buy batteries under that condition, but also the idea of buying a brand new Zero for no good reason has been made to feel like extortion. I suspect that if I try to rebuild the batteries myself, it'll still cost a lot, and I'll lose patience and make a big mess of it, it'll be a fire risk and it won't be sufficiently roadworthy.

[Specter]

Curt, sadly in our throw away society that we all live in now, that's very popular.  They don't want you to fix the old, they want you to pitch it and buy a new.  LONG gone are the days of bragging how long their old stuff lasts, hats off to the Maytag repairman, now it's how new, their latest garbage is, they brag on.

Aaron

[electrictwowheeler]

There are 3 - 14.4 batteries on Ebay right now. Priced from $2,600 to $3,500 plus a few hundred in shipping. There is a YouTube video of a guy who replaced the battery in a DSR. It looks pretty straight forward. Check with Zero to see if they will fit all 2013 and newer bikes.

[TheRan]

You have to be careful with buying batteries on their own. There's one that keeps getting listed here in the UK for really cheap, the sellers been trying to get rid of it for probably a year and presumably it's just been sitting around and not charged the whole time (and who knows how long before it was listed the first time) and because it's not in a bike there's no way to check the state of charge on it.

[electrictwowheeler]

According to the seller, one of those used batteries is still in the bike. I would think you could check the voltage if you removed the dog house cover, that is just speculation on my part. I bought a 2021 SR with 400 miles on it and a charge tank for $5,000 from a dealer last summer. It still has battery warranty left. I was recently offered a 2020 Harley Livewire one by a different dealer for $10,000 ! Maybe Aaron is right about the bikes being disposable, you can buy a complete used bike for less than a new battery. As I remember Zero used to claim the battery was good for the life of the bike. The battery life IS, pretty much the life of the bike.

[Specter]

snip...  the battery  IS the life of the bike... snip snip.

NOW you are catching on to the meaning and value of advertising words and claims.

the battery is still 'good'  it's just at 40 percent of it's original capacity, 'good' meaning it'll turn the bike on and let you get down the block.

one would also expect the price of batteries to be coming way down as the tech matures etc too right?  not so much.... tarriffs and  other nonsense excluded.  THAT is their money maker, just like how a tablespoon of ink can cost you 40 dollars.  THAT is how they get you, only for us, it's the battery.

aaron